Process of making paperboard carrier for static cling vinyl products

ABSTRACT

This invention relates to a process of making paperboard materials for carrying static cling vinyl products for transport to end users. Such structures of this type, generally, provide good adhesion for the static cling vinyl product, but allow the vinyl product to be peeled off easily.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to paperboard materials for carrying static clingvinyl products for transport to end users. Such structures of this type,generally, provide good adhesion for the static cling vinyl product, butallow the vinyl product to be peeled off easily.

2. Description of the Related Art

It is known, in current carriers for static cling vinyl products, toemploy a poly-coated cast-coated paperboard. Exemplary of such prior artis U.S. Pat. No. 4,652,239 ('239), to B. J. Brimberg entitled "SpacePlanning System and Method". While the cast-coating of the '239 patentprovides a smooth surface for retaining the static cling vinyl products,the cast-coated material of the '239 patent is not readily available andis very expensive. Consequently, a more advantageous carrier, then,would be presented if the expensive cast-coated material could beeliminated.

It is apparent from the above that there exists a need in the art for acarrier for static cling vinyl products which is light weight, and whichat least equals the static cling characteristics of the known carriers,but which at the same time eliminates the use of the expensivecast-coated material. It is the purpose of this invention to fulfillthis and other needs in the art in a manner more apparent to the skilledartisan once given the following disclosure.

SUMMARY OF THE INVENTION

Generally speaking, this invention fulfills these needs by providing amethod for producing a paperboard carrier for static cling vinylproducts, the steps comprising: extruding a layer of a polymericmaterial substantially over a paperboard carrier base; contacting saidextruded layer with a cooling means in order to substantially smooth outsaid extruded layer; surface treating said extruded layer to raise asurface energy of said extruded layer to provide adhesion between saidpaperboard carrier and said static cling products; and securing a staticcling vinyl product to said extruded layer.

In certain preferred embodiments, particulate minerals preferably, clay,may be coated on the paperboard base. Also, the polymeric material ishigh density polyethylene (HDPE). Also, the cooling means is a chillroll. Finally, the step of surface treating is accomplished through theuse of a corona discharge or flame treatment.

In another further preferred embodiment, the paperboard carrier providesgood adhesion for the static cling vinyl product, but allows the productto be easily peeled off.

The preferred carrier, according to this invention, offers the followingadvantages: excellent adhesion for static cling vinyl products;lightness in weight; ease of assembly; good stability; good durability;good economy; and ease of static cling vinyl product removal. In fact,in many of the preferred embodiments, these factors of excellentadhesion and ease of product removal are optimized to the extent that isconsiderably higher than heretofore achieved in prior, known carriers.

The above and other features of the present invention, which will becomemore apparent as the description proceeds, are best understood byconsidering the following detailed description.

DETAILED DESCRIPTION OF THE INVENTION

Initially, a paperboard base having a thickness of between 0.007 to0.035 inches is coated on one side with a coating of particulateminerals, preferably, clay. However, it is to be understood that theparticulate coating may be omitted. The paperboard may be formed frombleached pulp stock or recycled paperboard.

After the paperboard base is coated with the particulate minerals, thecoated side of the paperboard base is then extrusion coated with highdensity polyethylene (HDPE). The extrusion coating is applied accordingto conventional techniques. After the extrusion coating is applied, achill roll which, preferably, has a rms value of less than one microinchis contacted against the HDPE extrusion coating. In this manner, thechill roll imparts a smooth surface to the HDPE layer.

After the HDPE layer has been smoothed, the HDPE layer is then treatedwith a conventional corona discharge or flame treatment in order toraise the surface energy of the HDPE layer. Once the HDPE layer has beentreated, a paperboard carrier for static cling vinyl products isproduced which provides adequate adhesion between the carrier and thestatic cling vinyl products. Finally, a static cling vinyl product isplaced upon the carrier for shipment to the end user.

It is to be understood that an extrusion of low density polyethylene(LDPE) or a coextrusion of LDPE and polyethylene terephethalate may beused instead of HDPE.

Once given the above disclosure, many other features, modifications orimprovements will become apparent to the skilled artisan. Such features,modifications or improvements are, therefore, considered to be a part ofthis invention, the scope of which is to be determined by the followingclaims.

What is claimed is:
 1. A method for producing a paperboard carrier forstatic cling vinyl products, wherein said method is comprised of thesteps of:coating a paperboard carrier base with a layer of particulateminerals; extruding a layer of a polymeric material substantially oversaid layer of particulate minerals wherein said polymeric material isfurther comprised of high density polyethylene; contacting said extrudedlayer with a chill roll in order to substantially smooth out saidextruded layer; surface treating said extruded layer to raise a surfaceenergy of said extruded layer to provide static such that adhesionbetween said paperboard carrier and said static cling vinyl products canbe achieved, wherein said step of surface treating is further comprisedof the step of corona discharge treating said extruded layer; andsecuring a static cling vinyl product to said surface treated, extrudedlayer.
 2. The method, as in claim 1, wherein said particulate mineralsis further comprised of:clay.
 3. The method, as in claim 1, wherein saidpolymeric material is further comprised of:a coextrusion of low densitypolyethylene and polyethylene terephethalate.
 4. The method, as in claim1, wherein said chill roll has an rms value of less than one microinch.